Process Intensification In Chemical Engineering Engineering Essay

Process Intensification In Chemical plan Engineering studyProcess Intensification (PI) is a fancy in chemic substance substance applied science which source defined punt in 1970 sparked by the need to reduce swell cost involved in a particular production arranging This was archetypical pioneered by ICI to reduce put great deal without sacrificing its production electrical condenser 1, Dautzenberg (Dautzenberg, et al., 2001).There was a first international conference in 1995, world-wide Conference for Process Intensification in the Chemical Industry. Ramshaw was the early scholar who worked on cognitive serve intensification philosophical foundation, defined PI as a dodging for making outstanding simplifications in the coat of it of a chemical coiffe to achieve a given production quarry (Ramshaw, 1995). Process intensification involves dramatic reduction in chemical base equipments by installation or genius(a) equipment volume as presented by (Ramshaw, 1995 ) and (Stankiewicz, 2003). By mentioning dramatic reductions, Ramshaw mentions of miniaturizing volume by the bless of 100 to 1000.This explanation by Ramshaw is quite contain and is cited in Stankiewicz (Stankiewicz, et al., 2000) as being too narrow that it discussed more on size reduction. PI can be defined as intensification on particular desired effect and size reduction is one of more or less(prenominal) desired results that can be achieved through PI. This definition is widened by Stankiewicz definition of functioning intensification as any chemical engineering development that leads to a substantially smaller, cleaner and more nix-efficient technology is touch intensification (Stankiewicz, et al., 2000).BHR Group defines movement intensification as Process intensification is a revolutionary approach to process and plant design, development and implementation. Providing a chemical process with the precise environment it take to flourish results in better products, a nd processes which atomic number 18 safer, cleaner, smaller, and cheaper. PI does not in force(p) re localize old, inefficient plant with stark naked, intensified equipment. It can challenge pipeline role models, opening up opportwholeies for new patentable products and process chemistry and change to just-in-time or distributed manufacture (BHR Group, 2003).This has been widely accepted (try to connect references) as definition of process intensification in chemical application.Process intensification can be categorise into ii types of approaches which ar (1) methodology-based approach and an other(a)(prenominal) one is (2) equipment-based approach. skeletal system Process intensfication and its components (from Stankiewicz et al. 2004).This study categorisation of dickens approach in process intensification is also presented and some of the latest existing industrial s oestrushs are given in an clause in The Chemical Engineer journal (King, et al., 2010).Reaction E ngineering involves size and bla bla blaReaction engineers spend a lot of efforts and ingenuity in enhancing nuclear nuclear reactors exertion by studying and implementing any optimum flight of steps for the answer arranging to be operated (Nicol, et al., 2001). bla bla blaIn reception engineering, equipment-driven approach is about reactor onward motion of rate of reaction by specific-volume, horniness shift and potful alter, whence may push chemical process or catalyst consummation to achieve the best out of their potentials. Nowadays this is done in term of enhancing conversion rates and reducing by-products formation by achieving concentration and temperature profiles 4, Multfunct.React. agar pp. 379-381 (Agar, 2004).Catalysis is one of examples of process intensification approach by methodology in general sense, as it serves a function to reduce activation energy required for a reaction to exceed. In chemical fabrication at that place are two major types of catalytic reactor builds, being the organize and random reactors. These categories are reviewed later in the next section regarding their benefits in reaction engineering process intensification.Some applications in chemical industry by process-intensifying equipment approach are integrating some(prenominal) unit trading trading operations or equipments into one multifunctional reactor, designing a new hybrid judicial separation such as reactive distillment and reactive absorption 2, Trans (Stankiewicz, et al., 2000). integrating in between two equipments as examples has been reviewed by Stankiewicz (2003) 5 Stamicarbons Urea 200plus technology. In this piece of music, the reactor is designed incorporated with condenser and known as consortium reactor. Size comparison shown that in this particular case size of equipment lessen to one-fourth of the pompous equipments (Stankiewicz, 2003) 5.The best reactor design and configuration is place in a particular chemical proces s by acquaintance available in its reaction chemistry, contacting pattern in terms of how and when individual elements reach through the reactor and contact one another and how long its identity changes. Furthermore, critical studies in reaction overall kinetics as well as its thermodynamics to which elements are exposed on their reaction trajectory is eventful in enhancing chemical reactor or in order to integrate reactor with any other unit operations.Through this reactor design concept, the most suitable reactor configuration is selected, e.g., ideal quid pro quo flow, packed-bed and etc.Overall kinetics bla.. bla.. bla..In considering thermodynamics, shake up transport inwardly or across the boundaries of reactor is a crucial consideration to put up optimised reaction in multifunctional reactor, based on their activation energy infallible for defenseless materials to react. In multifunctional reactor this is the scope where energy would be supplied or removed from an endothermic or exothermic principal(prenominal) reaction to cite a forward drive of chemical reaction. Energy balances are important at this stage and establishing temperature profile is take from analysis for purpose of chemical reaction intensification. Methods of combust get rid of are also reviewed as on that point are categories of disturb enrapture methods known to be efficient in a particular reaction.This is the normal and widely accepted proceduresomebody reactor design such as static mixer reactor, big reactor, spinning disk reactor and etc, are examples of equipment-driven approach in process intensification (Stankiewicz, 2003). This examples are actually concepts revolves on developing component design and melioration of a particular reactor.Development ofModelling of process intensification. primary(prenominal) move aPI Area of Concern in Reaction Engineering Applications.Heat supervene upon in reaction engineeringnuclear reactor normally contains high amou nt of energy namely heat as reaction is progressing with reactor usually being operated at the highest temperature compare to other equipment upstream and downstream. This is essential to the reactions as thermal energy required for molecular bond to form or dissociate.Heat exchange in reaction engineering design has been analyse extensively as heat transfer plays a significant role in all chemical reactions. Agar D.W. (2004) (Agar, 2004) has categorised heat transfer into four categories, namely convection, recuperation regeneration and reaction (Figure ). This categorisation helps a lot in providing the best heat transfer solution in knowing which the best reactor configuration is in adding or removing heat.Figure Heat transfers for manipulating temperatures and concentration profilesin chemical reactors (from Agar, 2004).Convection is additional or removal of side-streams which intentionally limits the availability of one reactant, hence, improving selectivity, e.g. cold-shot reactor. In recuperation heat transfer at that place is an external heat transfer sources and sinks which operates to generate temperature differences in between reaction phase and rut mean(a) by taking in or removing heat somewhere else, e.g. temperature reduction towers, fin fan coolers, heat exchangers and etc. Regeneration heat transfer makes use of the reactor internals, usually beds or fisticuffss as an accumulation of heat and good deal in order to establish temperature profile and also concentrations. This temperature could not increase when in steady-state operation (Agar, 2004). Reaction is a straight-forward junto of main reaction with compatible supplementary reaction either thermally or materially, e.g. oxyhydrogenation (Agar, 2004).Operating temperature is achieved in reactor by one of these heat exchange approaches using various kinds of reactors accessories in multifunctional reactor such as heat jacket, tubes heat tracing or less commonly by heating coil.Mass transfer in reaction engineeringIntegration of mass transfer and catalyst has been studied (since, whom, what are achievement so far.) and conspicuously applied in reactive distillations which will be reviewed in inside information below.Packing shapesMultifunctional reactors development. e.g Pool reactor, reactive distillation tug, heat exchanger reactorMultifunctional reactors are reactors that serve umteen functions of unit operations in single equipment. These reactors usually combined with separators either distillation or absorber, or with heat transfer equipments such as cooler, heater or condenser. Some of the examples arePool reactors (reactor-condenser)Reactive distillation towboatsPool reactor were discussed in Stankiewicz 2003 5 (Stankiewicz, 2003), where combination of reactor and condenser yielded a novel equipment. Worlds first pocket billiards reactor is known developed by DSM Research back in 1945.A type of multifunctional reactor in which combined reactor and condenser was studied in details by Ben Amor et al (1999) (Ben Amor, et al., 1999) took methanol synthesis from its raw material, syngas in prototypes as main scope.(Add a bit of elaboration for forward motion achievement).This is further developed and analysed in Haut, et al (2004) (Haut, et al., 2004)Heat exchanger reactor is designed by combining reactor, heat exchanger and scrub brush by thePI in multifunctional reactor design.Multifunctional reactor has been a good example of process intensification by equipment-driven approach. Process intensification in multifunctional reactors were presented inPros Examples in estimableCons ThereSeveral functions or processes are designed to occur at the same time in multifunctional reactors. One of many examples of these reactors is fluidised catalytic cracker (FCC) that has two reactions occur in one unit operation namely cracking and another is removal of coke in hydrocarbon (Dautzenberg, et al., 2001).IssuesImplementationMAIN PARTS b Chemical reactors often utilize catalysts in its operations as they stomach easier path for reaction to happen that the activation energy is lowered with their charge in reaction phase. Two general categories of catalytic reactor configuration are random catalytic reactor and structured catalytic reactor. unified catalysts has been paid attentionRandom catalystsReactive distillation is one of many examples of process intensification in multifunctional reactor.One of many good examples in process intensification by desegregation of unit operations is the reactive distillation in which reaction phase is put together with separation phase in single equipment. This has been call as pool reactor (Stankiewicz, 2003 5) (Stankiewicz, 2003). Reactive distillations uses towboat wadding which made by the catalyst material as the reactants pass through the column will react and the separation takes place along the column throughout the packingThis was initiated by the studies.. where colu mn internals which use naturalized packing shape with materials that could probably be replaced with catalytically compatible materials to set about forward reaction equilibrium for more yields.An example of this ground-breaking new packing is Super X-pack (structured packing) designed and manufactiured by Nagaoka International Corp., able to reduce size of column down to five times smaller compares to conventional column and much lower pressure drop across the packing. This dramatic reduction of equipment size was illustrated as comparison to conventional applications by Stankiewicz (2003) 5 (Stankiewicz, 2003) as shown in go into (Figure ).Figure Super X-pack revolutionary packing fordistillation columns by Nagaoka International Corp.Sulzer Chemtech developed KATAPAK-S packing as catalytic packing and this is packing has been studied in details regarding the geometry of flow channel, hydrodynamics and mass transfer performance in Behrens et. al. (2006) 9 (Behrens, et al., 2006 ). Modelling of liquid hold-up, pressure drop and mass transfer were conducted specifically based on this Sulzers KATAPAK-S as the main pore in this publication. This knowledge is crucial for further developments and applications. Stankiewicz (2003) (Stankiewicz, 2003) is also cited in this paper in terms of combining reactors and separators.Future enquiryes on these Super X-pack and Sulzers KATAPAK-S are potential development of catalytic version of this packing. From process-intensification point of view this could by chance be the breakthrough shift in vast reduction of column size and a key step up in reactive distillation that will bring a extensive benefits in chemical industry.Parkinson (2000), Drip drop in column internalsApplications in Chemical Industry.catalytic reactive distillation has been commercially used in chemical industry (DeGarmo J.L., 1992) 8 (DeGarmo, et al., 1992). One of the examples of applications in chemical industries is the Methyl Acetate separative r eactor technology development by Eastman Chemicals. This is presented by Siirola (1995) 12 (Siirola, J. J. Eastman Chemical Company, 1996). This has been cited in Stankiewicz (2003) 5 to ponder the extensive reduction in plant size. This massive plant size of seven tasks is integrated into single piece of equipment. Distillation, extractive distillation, reaction, reactive distillation are the discrete tasks which have been combined into one column. As the result, numbers of equipment are reduced to 3 from conventional plant that has 28 equipments. This is shown in figure (label figure below)Figure 4 Plant integration in methyl radical acetate separative reactor process by Eastman Chemical(from Siirola 1996 13).Benefits (to appertain this point of integration benefits in between 5, Stankiewicz, Ramshaw,1999 cost reduction and 6, Hendershot sanctuary regarding integrated unit operation e.g. pool reactor, in reactive distillation) toll reduction on the major plant item was the pri mary objective of PI, but other benefits comes along with this reduction of costs such as structural work, earth/civil work for large vessel foundations, installations and outwear as well as less pipe work needed (Ramshaw, 1999).While looking into process intensification from safety point of view this equipment integration .. (Hendershot, 2004)This can reduce the risk of reaction stage while in operation as reducing the size of the plant means minimising uncivilised material usage concept proposed by Kletz (Kletz, 1996). The possible opportunity for chemical fugitive through pipe connection in between unit operations is also eliminated as what you dont have cant leak (Kletz, 1978). This simpler plant is the result one looking for in achieving the objective in process intensification. Smaller plant is one of the objectives in process intensification and parallel with the concept of mentioned above in introduction (Stankiewicz, et al., 2000).Potentials of further development of reac tive distillationPool reactor was started as RD program by DSM Research back in 1945 and after 51 years, the technology was established and patented in 1996 in urea production known as Urea 2000plus technology. The first commercial plant was commissioned in 1998 when start-up of first Urea 2000plus pool reactor plant.Stamicarbons Urea 2000plus technology reduced the size of installed equipments from early introduction at total height of 78 metres .. (Bakker, 2004).ReactorStrippercapacityScrubberPool CondenserPool ReactorUrea 2000plus technologyConventional urea technologyCUsersdynaPicturesMP Navigator EX2010_10_03Urea 2000Plus Pool Reactor2.jpgFigure 5 Reduction of size by integration of reactor, condenser and scrubber featured in StamicarbonsUrea 2000plus technology (from Bakker, 2004).MAIN PARTS cModelling of process intensification.ModellingModelling of Krishna Taylor (2000)MAIN PARTS dProcess intensification for safety.In establishing a chemical plant nowadays, there are massi ve lists of safety legislations need to be adhered. One of the best practices in chemical industry is to construct a plant with elements of immanent safety. inbred safety and intrinsic safety mean the same and would be used interchangeably from this point onwards. Process intensification is an important aspect that needs to be implemented in achieving an inherently safer chemical process and plant.Process intensification for inherent safety concept has long been establish has beenIntrinsic safety in reactor configuration and operation is a crucial element since reactor is a heart of a chemical manufacturing plant. Being the centre of a process containing various components of chemicals as raw materials are introduced and as reactions took place there would be mixture of products and normally more than two by-products. Reactor also traditionally contains high amount of energy namely heat as operating with usually being operated at the highest temperature compare to other equipment upstream and downstream. This is where energy would be supplied or removed as declared before in the introduction.From the point of equipment integration reviewed before, reactor combination with other unit operations such as distillation, condenser, scrubber or heat exchanger is another approach in process intensification, i.e equipment-driven approach (King et. al. 2010) 10.MAIN PARTS eBarriers and potential prospects of process intensification in reaction engineering. likewise wide-ranging advancement in PI in reaction engineering, there are several difficulties known in holding back the research and implementation of technologies. This occurs especially in upscaling from lab or pilot eggshell to commercial photographic plate.In 1998 AIChEs Center for Waste Reduction Technologies organised two workshops that has recognised barriers for reactive/hybrid separations and as agreed there were cardinal categories of technical and nontechnical difficulties which areTechnical gaps, su ch as deficiency of simulation and scale-up capability, pretermit of validated thermodynamics and kinetic data, lack of materials (compatible materials, e.g., integrated catalysts/sorbents, tissue layer materials) as these materials have to be developed specifically for the purpose of new process chemistry, and lack of high-level process synthesis methodology.Technology transfer barriers, lack of experts in multidisciplinary team in process integration approach, lack of communality of problems (each application has unique technology) and lack of models/prototypes on a reasonable scale (most of the studies still regarded as science which involves small-scale researches).General barriers, such as higher standards, to require implementation of new technologies, as opposed to conventional technologies, lack of process economics (as new technologies have not been be to be feasible as there is no commercial model available) and fear of risk in operating new technologies.Besides those d ifficulties, time to come opportunitiesCONCLUSIONSThe implementations of process intensifications transform conventional chemical engineering unit operations into a revolutionary process technology whether by integration of several unit operations or by altering intrinsic chemical process elements to eliminate unnecessary process bottlenecks. Changes usually measured by the substantially cost improvement, progress delivery/process time, 3, Re-Engineering chem